Color printed laminated structure, absorbent article comprising the same and process for manufacturing the same

ABSTRACT

The present invention relates to a color printed liquid permeable laminated structure comprising a first liquid permeable layer and a second liquid permeable layer, the first layer is color printed on at least one of its surfaces prior being laminated to the second layer and stabilizing the laminated structure with a bonding means. These color printed laminated structures are particularly suitable for use in disposable absorbent articles for feminine protection, typically as so called ‘secondary’ topsheet in face to face relation with so called ‘primary’ topsheet, through which they are visible.

FIELD OF THE INVENTION

[0001] The present invention relates to a liquid permeable color printedlaminated structure comprising at least a first and a second layer, thesecond layer being a fibrous web, preferably a dry laid fibrous web, thefirst layer being color printed on one of its surface before applyingthereto fibers to form the fibrous web and stabilizing the resultinglaminated structure. The present invention also relates to a process formanufacturing such a color printed laminated structure and to disposableabsorbent articles comprising such a color printed laminated structuretypically as a so-called secondary topsheet directly underlying theprimary topsheet of the articles.

BACKGROUND OF THE INVENTION

[0002] Conventional absorbent articles normally comprise a liquidpermeable (pervious) topsheet having a user-facing surface, a liquidimpermeable (impervious) backsheet having a garment-facing surface andan absorbent core located intermediate the topsheet and the backsheet.

[0003] These elements of absorbent articles like feminine protectionarticles namely sanitary napkins and/or panty liners, are typicallyprovided in white color, thereby providing a hygienic condition. Uponbody fluid discharge like menstruation the absorbent article, typicallythe absorbent core, absorbs colored body fluid, and changes color tothat of the fluid being absorbed. This is distasteful to the user. Itis, therefore extremely desirable to provide a clean appearance and adry surface after the discharge of colored body fluids thereon.

[0004] Also each menstrual period is very troublesome for women andalmost all the women are in a depressed mood during menstruation. It hasbeen found that there is thus a need for an absorbent article forfeminine protection with which a woman may be relieved from amelancholic mood and may experience menstruation without distress orinconvenience.

[0005] This problem could be addressed per absorbent articles with acolor printed non-woven as the topsheet. Although in the field ofabsorbent articles for baby protection it is known to color printnon-woven (especially the backsheet of diapers), the use of thistechnology in absorbent articles for feminine protection as a topsheetdirectly facing the wearer's skin still encounters negatives like colorbleeding and/or color rub-off towards the wearer's skin, this especiallyunder wet conditions per discharge of body fluids on the articles.

[0006] Furthermore the use of color printing technology on for examplebody fluid receiving/transmitting elements/layers of absorbent articlesshould not jeopardize the primary benefits of said elements/layers andhence of the overall body fluid handling properties of the articles perse.

[0007] It is thus an object of the present invention to provide anabsorbent article for feminine protection which provides a pleasantfeeling to a woman before she uses it and which is so structured as tobe disposed off cleanly while concealing the flow once the article isused.

[0008] It is a further object of the present invention to provideimproved colored printed elements/layers for use in absorbent articlesfor feminine protection typically as topsheet (preferably as secondarytopsheet) with reduced color bleeding and reduced color rub-off withoutcompromising on the inherent acquisition, diffusion/transmission andabsorption properties of such elements/layers.

[0009] It has now been found that these objects are solved by providinga color printed liquid permeable laminated structure comprising at leasta first layer and a second layer, each layer having a first outersurface and a second outer surface, the two surfaces being opposite eachother, the first layer being color printed on at least one of itssurfaces (i.e., at least on its first or second surface or both) priorbeing laminated to the second layer, the second layer being a fibrousweb, preferably a dry laid fibrous web, the laminated structure beingstabilized by a bonding means preferably a latex binder, and a processfor manufacturing such a laminated structure.

[0010] Advantageously by color printing the first layer, preferably anon-woven, prior laminating it to fibers to form a fibrous (dry-laid)web and stabilizing the resulting laminated structure per bonding means,preferably latex binder, the laminated structure retains essentially allits acquisition, diffusion and absorption properties towards body fluiddeposited thereon. In contrast, color printing as a subsequent step, alaminated structure after having laminated a first layer, e.g., anonwoven, to a (dry laid) fibrous web and stabilized the resultingstructure per bonding means, results in lost of acquisition, diffusionand absorption properties of the laminated structure. Indeed, printingwith conventional printing technologies known to those skilled in theart (e.g., flexography) one surface of such a laminated structure (oncelaminated) results in caliper reduction of the whole laminated structurethickness, thereby increasing the density of the fibrous dry laid web,and hence reducing its body fluid handling properties.

[0011] Advantageously stabilizing the color printed laminated structureof the present invention by applying a bonding means preferably a latexbinder contributes to reduced color bleeding and reduced color rub-off.

[0012] In a broadest aspect the present invention also encompasses anabsorbent article for feminine protection comprising a liquid permeabletopsheet, an underlying layer directly adjacent to the topsheet andvisible through the liquid permeable topsheet, a liquid impermeablebacksheet and an absorbent core positioned between the underlying layerand the backsheet, the underlying layer visible through the topsheet isa color printed liquid permeable laminated structure comprising at leasttwo liquid permeable layers, each layer having a pair of opposedsurfaces, at least one of said layers of the laminated structure iscolor printed on at least the surface directly adjacent another liquidpermeable layer of the laminated structure, prior laminating the liquidpermeable layers of the laminated structure together. Advantageouslysuch construction results in reduced color bleeding and reduced colorrub-off towards the topsheet while not compromising on the body fluidhandling properties of the article.

BACKGROUND ART OF THE INVENTION

[0013] Ink-printed non-woven fibrous webs and absorbent articlescomprising the same are known in the art.

[0014] Representative of the art are the following references:

[0015] U.S. Pat. No. 5,458,590 discloses ink-printed non-woven fibrousweb comprising a non-woven fibrous web comprising a pair of opposedsurfaces, and an image printed with an ink on one of said surfaces, saidnon-woven fibrous web having an average wet crockfastness value of atleast about 4 or greater. '590 also discloses disposable absorbentarticles comprising a topsheet, a backsheet and an absorbent composite,the backsheet comprising such a ink-printed non-woven fibrous web.

[0016] EP-A-934 737 discloses an absorbent article comprising atopsheet, a backsheet and an absorbent core intermediate the topsheetand the backsheet. The topsheet includes a primary topsheet and asecondary topsheet. At least some of the primary topsheet has aperturesarranged in a regularly spaced first pattern. At least some of thesecondary topsheet has indicia arranged in a regularly spaced secondpattern, the indicia being positioned, shaped and dimensioned to besubstantially homogeneously visible through the apertures in a first ornon-position, the secondary topsheet being pivoted relative to theprimary topsheet by a pivot angle from the first position to a second orin-use position so that the indicia of the secondary topsheet aredifferentially out of alignment with the apertures of the primarytopsheet, forming a regularly spaced third pattern. The regularly spacedthird pattern facilitates correct positioning of the absorbent articlewhilst, simultaneously, masking any colored fluid absorbed by theabsorbent core.

[0017] None of these prior art discloses, nor teaches the color printedlaminated structures as presently claimed, nor absorbent articlescomprising the same, let alone a process for manufacturing the same.

SUMMARY OF THE INVENTION

[0018] The present invention relates to a color printed liquid permeablelaminated structure comprising at least a first liquid permeable layerand a second liquid permeable fibrous layer, preferably a dry laidfibrous web, the first layer is color printed on at least one of itssurfaces prior being laminated to the (dry laid) fibrous web andstabilizing the laminated structure with a bonding means, preferably alatex binder. The present invention further relates to a process ofmanufacturing such a color printed laminated structure.

[0019] In its broadest aspect the present invention also encompasses anabsorbent article for feminine protection comprising a liquid permeabletopsheet, an underlying layer visible through the liquid permeabletopsheet, a liquid impermeable backsheet and an absorbent corepositioned between the underlying layer and the backsheet, characterizedin that the underlying layer visible through the topsheet is a colorprinted liquid permeable laminated structure comprising at least twoliquid permeable layers with a pair of opposed surfaces, at least onelayer of the laminated structure (typically the so-called first layer inthe description herein) is color printed on at least one of itssurfaces, preferably at the surface directly adjacent another liquidpermeable layer of the laminated structure, prior laminating the liquidpermeable layers of the laminated structure together.

BRIEF DESCRIPTION OF THE DRAWINGS

[0020] While the specification concludes with claims particularlypointing out and distinctly claiming the present invention, it isbelieved that the present invention will be better understood from thefollowing description in conjunction with the following drawings:

[0021]FIG. 1 is a schematic, fragmentary side elevational view of anapparatus for making a laminated structure according to the presentinvention;

[0022]FIG. 2 is an enlarged cross-sectional view of a color printedlaminated structure according to the present invention;

[0023]FIG. 3 is an enlarged cross-sectional view of an alternativeembodiment of a color printed laminated structure according to thepresent invention;

[0024]FIG. 4 is an enlarged cross-sectional view of a feminineprotection absorbent article taken along line I-I of FIG. 5;

[0025]FIG. 5 is top view of a feminine protection absorbent articleaccording to the present invention;

[0026]FIG. 6 is an alternative top view of a feminine protectionabsorbent article according to the present invention.

DETAILED DESCRIPTION OF THE INVENTION

[0027] Definitions

[0028] The term “absorbent article” as used herein embraces articles,which absorb and contain body exudates. More specifically, the termrelates to articles placed against or in proximity to the body of a userto absorb and contain the various exudates discharged from the user'sbody. The term “absorbent article” is intended to include baby diapers,sanitary napkins, panty liners, incontinence products. However, articlessuch as sweat-absorbent underarm pads, nursing pads, collar inserts,absorbent wound dressings and any other articles used to absorb bodyfluids or body exudates can also benefit from the present invention.

[0029] The term ‘disposable’ is used herein to describe absorbentarticles that are not intended to be launched or otherwise restored orreused as absorbent articles (i.e., they are intended to be discardedafter a single use and, preferably to be recycled, composted orotherwise disposed of in an environmentally compatible manner).

[0030] The term “use”, as used herein, refers to the period of time thatstarts when the absorbent article is actually put in contact with theanatomy of the user.

[0031] In a preferred embodiment of the invention the color printedlaminated structure consists of two layers, i.e., the first and secondlayers, as described herein after. In such executions the term “innersurface” of respectively the first and second layer of the laminatedstructure, refers to the surface of the first layer facing the secondlayer and to the surface of the second layer facing the first layer, the“outer surface” of respectively the first and second layer isaccordingly respectively the opposite surface of each layer. In otherwords, in the preferred embodiment wherein the laminated structureconsists of the first and second layers, the outer surfaces of the firstand second layers form the outer surfaces of the laminated structure.

[0032] Color Printed Laminated Structure

[0033] The present invention relates to a color printed liquid permeable(fibrous) laminated structure primarily intended for acquiring,diffusing and absorbing fluids, typically body fluids. The structurecomprises at least two layers, a first layer that is color printed on atleast one of its surfaces and a second layer, the so-called fibrous web.In preferred embodiment herein the color printed fibrous laminatedstructure consists of only the first and second layers as describedherein.

[0034] In a preferred embodiment, the laminated structures of thepresent invention are incorporated into absorbent articles, intended forabsorption of body fluids. Preferably it is used as topsheet, morepreferably as a secondary topsheet underlying a primary topsheet. Such asecondary topsheet is intended to acquire and diffuse body fluidsthrough the primary topsheet towards the absorbent core. Alternativelythe color laminated structures according to the present invention canconstitute integrally the absorbent core of a disposable absorbentarticle, or they can be comprised therein as part of the absorbent core.

[0035] It has surprisingly been found that by color printing a firstliquid permeable layer prior laminating it to a second liquid permeablelayer, preferably a (dry laid) fibrous web and stabilizing the resultingstructure per bonding means, preferably a latex binder, a color stableprinted liquid permeable laminated structure is provided that retainsits acquisition, diffusion and absorption properties towards bodyfluids.

[0036] Advantageously the color printed laminated structure according tothe present invention has improved color bleeding resistance thatreduces the transfer of printed ink to other surfaces/layers andimproved color rub-off resistance, while retaining desired physicalcharacteristics of the laminated structure as a whole, like softness,drapability, thickness, wettability and fluid acquisition speed.

[0037] In a preferred embodiment herein the color printed laminatedstructures according to the present invention meet at least one of theparametric features specified herein after and preferably all of them.Indeed the color printed laminated structures according to the presentinvention typically have a color fastness to water when measuredaccording to ISO 105-E01 of at least 3, preferably of 4 or more,typically a color fastness to rubbing when measured according to ISO105-X12 in dry condition of at least 3, preferably 4 or more and in wetcondition of at least 2, preferably of 3 or more, and typically a colorfastness to perspiration when measured according to ISO 105-E04 of atleast 3 and preferably of 4 or more (for independently both alkalinesolution and acid solution). These test methods are standard ones asdescribed in respective ISO test (International Organization forStandardization). The measures are performed on a scale of 1 (the worstrating) to 5 (the best rating) as provided in these test methods.

[0038] Highly preferred herein the color printed laminated structure isa dry laid laminated structure described in more details herein after.

[0039] The dry laid manufacturing process used herein comprises a webformation and layering step and a web bonding and stabilizing step; indry laying processes in fact the fibres, that can be of any type, e.g.cellulosic, synthetic, or any combination thereof, are formed orcondensed into a web. Further components that are not in fibre form canalso be incorporated in the fibrous web, e.g. a particulate materiallike an odour controlling agent and/or superabsorbent material asdesired. The resulting web lacks integrity after formation, and musttherefore be stabilized. Different techniques for bonding andstabilizing a dry formed web might be used herein including mechanical,thermal and chemical bonding processes. Bonding a web structure by meansof a chemical is one of the most common methods of bonding in thenon-woven industry, and consists in the application of a chemical binderto the web and in the curing of the binder, preferably latex binder.Advantageously latex is cheap, versatile, easy to apply, and veryeffective as a binder. Several methods might be used to apply the latexbinder to the fibrous web, while spray bonding and print bonding areparticularly preferred for fibrous webs intended to be used in absorbentarticles.

[0040] First Layer of the Color Printed Laminated Structure

[0041] The first layer is liquid permeable (in other words fluidpervious) permitting body fluids (e.g., menses and/or urine) to readilypenetrate through its thickness.

[0042] A suitable first layer can be manufactured from a wide range ofmaterials such as woven, non-woven materials, knits, and films. Suitablewoven and non-woven materials can be comprised of natural fibers (e.g.,wood or cotton fibers), synthetic fibers (e.g. polymeric fibers such aspolyester, polyolefin fibers such as polypropylene or polyethylenefibers), a combination of natural and synthetic fibers orbi-/multi-component fibers.

[0043] Examples of commonly employed polyolefins are polypropylene andpolyethylene, including low density, high density, and linear lowdensity polyethylene. It should be appreciated, however, that thepresent invention is not limited to these types of polyolefins, andembraces all types of polymers, copolymers, and natural fibers. In wovenmaterial applications, these materials can be made into continuousfibers, which are in turn woven into a fabric. In nonwoven applications,the fibers may be long, generally continuous fibers, such as spunbondand meltblown fibers, or they may be shorter staple length fibers, suchas are commonly used in carded webs. Such polymers or copolymers may beextruded, cast, or blown into films for subsequent use according to thepresent invention.

[0044] The fibers used in the first layer of the laminated structureherein can be “straight” fibers in that they have the same generalpolymer or copolymer composition throughout. The fibers may also bemultipolymer or multicomponent fibers, such as bicomponent fibers inwhich at least one component is a polyolefin, such as a polyethylenesheath and a polypropylene core fiber, or a polyethylene sheath and apolyester core fiber. In addition to sheath/core fiber configurations,other examples of suitable fiber cross-sections are side-by-side,sea-in-islands, and eccentric fiber configurations. Furthermore, fiberswith non-circular cross-sections such as “Y” and “X” shapes may be used.

[0045] The fibers and/or webs may have other components and/ortreatments. For example, adhesives, waxes, flow modifiers, processingaids and other additives may be used during the formation of the fibersand webs. In addition, pigments may be added to the fibers to changetheir color and other additives may be incorporated into thecompositions to make the fibers and/or webs elastic. Lastly, blends offibers, as well as straight and bicomponent fibers, may be combined toform nonwoven webs suitable for use as the first layer of the laminatedstructure of the present invention.

[0046] When forming a nonwoven, such as a nonwoven polyolefin fibrousweb, the fiber size and basis weight of the material can be variedaccording to the particular end use. In personal care product, typicalfiber sizes will range from between about 0.1 to about 10 denier, andbasis weights will range from between about 10 grams per square meter toabout 105 grams per square meter. For other applications, both the fibersize and the basis weight can be adjusted.

[0047] Examples of suitable first layer for use herein are spunbondedpolypropylene nonwoven, 17 gsqm, commercially available from BBA (fullname) under code 1WH05-01-17B and/or spunbonded polyethylene nonwoven,17 gsqm, commercially available from BBA Lynotec under name T27AXC.

[0048] It is an essential feature of the invention that the first layeris color printed on at least one of its surface. Color printing processis described herein below in more details.

[0049] The inherent color of the first layer material might affect thecolor printing especially of lighter tints color printing. It will beappreciated that color printing are more distinct against a soft(yellowish) white, whilst process colors reproduce most accurately onneutral white material. The brightness of the first layer material maybe altered, to adjust the contrast or brilliance of the color printing.Color reproduction may be affected if artificial brighteners (e.g.,fluorescent additives) are incorporated in the first layer material,since most artificial brighteners are not neutral in color but, rather,have excess blue reflectance. Although per se the first layer might becolored (i.e., might have another color than white) it is highlydesirable that the first layer per se is not colored, i.e. is white,prior undergoing color printing as described herein after.

[0050] Whatever surface of the first layer that is color printed, theresulting colored print is visible not only on the surface printed butalso through the thickness of the first layer on its opposite surface(i.e. surface of the first layer being opposite to the one printed).Thus in the embodiments herein wherein the color printing occurs on thefirst layer on at least the surface thereof directly adjacent to thesecond layer in the laminated structure, prior laminating the firstlayer to the second layer, the color print is visible through thethickness of the first layer on its opposite surface (which, in thepreferred structure herein consisting of only two layer, i.e., the firstand second layers, corresponds to the outer surface of the laminatedstructure). This is achieved per the properties of the first layer, forexample nonwoven, such as fibers transparency, and/or open area percentwithin the first layer and/or low basis weight. It is common practice tothose skilled in the art to vary such parameters to obtain the desiredrelative transparency. Alternatively transparency might be obtained perheat application and/or pressure, for example per application of anembossment pattern.

[0051] The first layer is color printed on at least one area of at leastone of its surfaces. At least one surface of the first layer is colorprinted following any desired image. Per ‘image’ it is understood hereinthe overall picture printed onto at least one surface of the layer. Theimage might cover only a limited area of the surface of the layer,typically in the center (so as for example to identify/visualize thebody fluid discharge area when used into a disposable article forfeminine protection), to the whole surface of the layer. The image canbe a plain color printing or can be made of various indicia composingthe image. Accordingly the image includes any form of color printingfrom uniform printing of only one color to multiple indicia of multiplecolors. Indeed, the image and indicia may be of various colors and/ortones, with different distributions and densities depending on therequirements of use. The image and indicia might have any size or shape.The image/indicia may be regular or irregular in shape. Suitableimage/indicia include, but are not limited to, any type of designs,marks, figures, identification codes, words, patterns, and the like.Example of image/indicia include, but are not limited to, triangles,tetragons, pentagons, hexagons, circles, ellipses, crescent-shapes,teardrops, ob-round shapes or a mixture thereof. In the case of aplurality of indicia forming the image, the color printed indicia can bethe same or different (color, shape and/or form), being irregularly orregularly spaced on the surface of the layer to which they are printed.

[0052] Examples of color printed images in absorbent articles are shownin FIGS. 5 and 6.

[0053] The colored image printed onto at least one surface of the firstlayer might be of any color, including only one color or combinationthereof. It will be appreciated that the color choice may have apsychological effect since, for example, red would be an “angry” colorwhilst blue would be a calming color or green a relaxing color. In aparticularly preferred embodiment according to the present invention,the color is selected within a range of colors from yellow to blue (440to 580 nanometers), i.e., colors being complementary to the colors ofmenstruation (dominantly red) and hence are able to absorb the redwavelengths of the light that are the ones reflected by a dominantly redcolor. Advantageously by color printing a layer with such a color orcombination thereof, the visibility of menstrual blood stains absorbedonto such a layer is reduced. In other words, the stains seem to besmaller and less vivid per visual inspection when using color printedlaminated structures according to the invention printed with colorsranging from yellow to blue (440 nm to 580 nm) in absorbent articles incontrast to color printed laminated structures printed with colorsranging from violet to orange. Considering that blood has not only onetonality, but a series of hues going from violet/magenta to orange,preferred colors used herein range from yellow to blue in order toprovide enhanced blood masking effect for all those tonalities.

[0054] In an alternative embodiment, if the first layer is pre-colored,the colored image may be applied in white ink. This gives a reversed,but sharper, impression of printed image.

[0055] The Second Layer of the Color Printed Laminated Structure

[0056] The second layer of the color printed laminated structure is afibrous web.

[0057] Fibrous web for use herein include spunlaced, wet laid web anddry laid fibrous web. Dry laid fibrous web are preferred herein anddescribed in more details herein after.

[0058] Dry laying and, more specifically, air laying processes arewidely used to produce webs from dry fibres. Particularly, dry layingrefers to the formation of carded webs, i.e., webs in which the fibresare oriented (carded) in a given direction, whereas the air layingprocess refers to the formation of webs with a completely random fibreorientation; the properties of such air laid webs are therefore somewhatisotropic. The fibrous webs produced by dry laying processes are soft,flexible and porous.

[0059] The fibrous structures of the present invention can be made usingconventional equipment designed for dry laying processes, and althoughthe invention is described hereinbelow with particular reference to airlaid structures, it should be understood that other dry layingprocesses, e.g. carding, are also applicable.

[0060] The dry laid fibrous web used in the laminated structure of thepresent invention is soft and yet strong and absorbent. It can bedesirable for preferred dry laid fibrous webs of this type to haverelatively low bulk. A reduction in bulk, which means a reduction involume the fibrous web is occupying, without sacrificing significantlyother desired properties is important from the standpoint ofmanufacturing, storage and packaging. Hence, for dry laid fibrous web(second layer) used according to the present invention the basis weightcan range from about 5 g/m² to 600 g/m², preferably from about 10 g/m²to 300 g/m², more preferably from about 20 g/m² to 100 g/m² and mostpreferably from about 40 g/m² to 70 g/m². Advantageously the strength ofthe laminated structure according to the present invention is providedper the first layer for example nonwonven, which acts as a carrier,giving the main strength to the resulting laminated structure. When thebasis weight exceeds the upper limit, the product may be too stiff andtherefore not useful for most applications.

[0061] The air laid fibrous web herein comprises randomly distributedfibres. Any of a variety of fibres, including a blend or admixture, canbe used in the fibrous web herein. The fibres may be cellulosic,modified cellulosic, or synthetic, and include such fibres as wood pulp,rayon, cotton, cellulose acetate, polyester, polyethylene,polypropylene, nylon, and the like. A fibrous web comprising cellulosicfibres such as wood pulp fibres is particularly useful for use as anabsorbent structure or topsheet in feminine protection absorbentarticles as sanitary napkins or panty liners because the cellulose isliquid absorbent, therefore enhances the overall absorbency of thelaminated structure as well as creates a network that contributes to thestrength of the overall structure and retains particles that might bepresent like for example polyethylene powder. Blend of cellulosic andsynthetic fibres might also be used, typically blend comprising about65% to 95% by weight of cellulosic fibres, and corresponding remainingpercent of synthetic fibres and more preferably up to about 20% byweight of the synthetic fibres. The synthetic fibres, which can beprovided in any length including staple length, can improve the strengthof the structure. They can also be treated to make them hydrophilic, inorder not to decrease the fluid handling properties of the fibrous web.

[0062] The Bonding Means

[0063] The laminated structure according to the present invention isstabilized per bonding means.

[0064] Suitable bonding means for use herein are any means able to bindthe fibers of the laminated structure and hence stabilize the laminatedstructure according to the present invention. Suitable bonding means foruse herein include any conventional binder known to those skilled in theart including but not limited to glue, adhesive, latex binder, heatsealable material like for example thermoplastic polymeric material

[0065] Highly preferred for use herein are latex binders, alone or incombination with other bonding means, preferably thermoplastic polymericmaterial.

[0066] For example latex binder is applied as an aqueous emulsion ordispersion, which typically contains about 2% to 20% solids, preferably2% to 10% solids, and such materials are readily available from severalmanufacturers. Because the latex emulsions are water miscible, they maybe further diluted, if desired, before being applied to at least onelayer of the laminated structure, preferably the outer layers. Also,these latex compositions are thermosetting, and in order to effectcross-linking, they contain a small amount of a suitable cross-linkingagent which are well known chemical agents for this purpose, such asN-methylolacrylamide. Any type of latex binder known in the art, whichis suitable for stabilizing (fibrous) laminated structures can be usedherein, provided that it preferably does not generate detectable odours,especially after curing, since this could be unpleasant for a user.Latices available are classified by chemical family, and thoseparticularly useful include vinyl acetate and acrylic ester copolymers,ethylene vinyl acetate copolymers, styrene butadiene carboxylatecopolymers, and polyacrylonitriles, and are sold, for example, under thetrade names of Airbond, Airflex and Vinac of Air Products, Inc., Hycarand Geon of Goodrich Chemical Co., and Fulatex of H. B. Fuller Company.The amount of latex binder used cannot be so high as to substantiallyimpair the fluid handling properties of the fibres, or as to impart astiffness to the structure to render it impractical. Typically the latexbinder may range from about 2% to 30% by weight of the laminatedstructure, and preferably from about 4% to 8% by weight.

[0067] The latex binder is applied on at least one of the outer surfaceof the laminated structure after having color printed the first layerand laminated it with fibres to form the dry laid web, therebystabilizing the whole structure and especially the fibres within the drylaid web, and hence preventing dust going out of the resulting laminatedstructure. Advantageously the latex binder also stabilizes the colorprinted image printed on one of the surface of the first layer of thelaminated structure, especially when the latex binder is applied on (theouter surface of) the first layer.

[0068] Preferably the latex binder is applied on both outer surfaces ofthe laminated structure, i.e. in the preferred embodiment herein theouter surface of the first layer and outer surface of the second layer,fibrous web, for optimum integrity/stability of the whole structure andoptimum reduction of color-bleeding and rub-off.

[0069] This later execution is illustrated in FIGS. 2 and 3, where boththe outer surface (2, 20) of the first layer (1, 10) and the outersurface (6, 60) of the second layer (4, 40) of the color printedlaminated structure (a, b) bear a latex coating, indicated in thedrawing by lines (8,9,80,90). The latex coating typically penetrates orimpregnates the structure to some degree and partially coats most of thefibres. The penetration might be controlled as desired so as not toimpair the characteristics of the laminated structure. Indeed the depthof penetration of the latex into the fibrous web (second layer) and/orfirst layer can be controlled by the vacuum applied by means of thesuction boxes positioned in correspondence with the dispensing meansdispensing the latex binder, and by the choice of the amount to beapplied.

[0070] In another embodiment of the present invention the bonding meansused herein is a thermoplastic polymeric material, alone or incombination with other bonding means, preferably latex binder.Optionally but highly preferred the fibrous web, especially dry laidweb, might comprise a thermoplastic polymeric material in finely dividedform, preferably in particle or powder form, beside the latex binder.Its distribution among the fibres of the dry laid web helps to bind thefibres upon thermal treatment. The subsequent thermal treatment meltsthe thermoplastic polymeric material and therefore creates a frameworkof discrete bonding points within the web, i.e. among the fibres wherethe thermoplastic polymeric material in finely divided form has beendistributed. The use of thermoplastic polymeric material in finelydivided form can advantageously be combined with latex bonding, e.g. thethermoplastic powder performs the bonding preferably of the innerportion of the dry laid web, while the application of a latex binderstabilizes the outer surfaces of the dry laid web. Typically thethermoplastic polymeric material may range from about 1% to 70% byweight of the total weight of the laminated structure, and preferablyfrom about 10% to 60% by weight.

[0071] The (dry laid) fibrous web used according to the presentinvention might comprise a particulate material distributed in the webthat is typically capable of performing absorption of aqueous fluidsand/or control of the odours, e.g., those odours associated with theabsorbed fluids. Preferably the particulate material comprises anabsorbent gelling material and/or an odour control means, both inparticle form.

[0072] The color printed laminated structures according to the presentinvention are illustrated in FIGS. 2 and 3. FIG. 2 shows a color printedlaminated structure (a) with a first layer (1) made of non-woven and asecond layer (4) being an air laid fibrous web, the first layer (1)having an outer surface (2) and an inner surface (3), the outer surface(2) being color printed, as indicated in the drawing per dotted line(7), the second layer (4) having an outer surface (6) and an innersurface (5), the structure being stabilized per latex coating on boththe outer surface (2) of the first layer (1) and the outer surface (6)of the second layer (4), indicated in the drawing by respectively lines(8,9). FIG. 3 shows a color printed laminated structure (b) with a firstlayer (10) made of non-woven and a second layer (40) being an air laidfibrous web, the first layer (10) having an outer surface (20) and aninner surface (30), the inner surface (30) of the first layer (10) beingcolor printed, as indicated in the drawing per dotted line (70), thesecond layer (40) having an outer surface (60) and an inner surface(50), the structure (b) being stabilized per latex coating on both theouter surface (20) of the first layer (10) and the outer surface (60) ofthe second layer (40), indicated in the drawing by lines (80, 90).

[0073] Examples of such color printed laminated structures illustratedin FIGS. 2 and 3 are laminates of two non-woven: The first layer can bemade of a 17 g/sqm spunbonded polypropylene non-woven material referredto as product No. 1WH05-01-17B (or ‘P-9’) obtained from BBA, Linotec,color printed on one of its surfaces. The second layer can be amulti-bonded air laid non-woven material that is thermally bonded usingpolyethylene powder and latex bonding. In a preferred embodiment, thismulti-bonded air laid non-woven material comprises about 60-70%cellulose fibres, 20-38% polyethylene powder and 2-10% of latex (40% oflatex is preferably sprayed on the first layer and remaining 60% thereofis sprayed on the second layer of the laminated structure) and has abasis weight of 40-100 g/sqm. These two non-woven layers are preferablylaminated together by deposition the multi-bonded air laid non-wovenmaterial on the spunbonded polypropylene non-woven material. Thespunbonded material is used as a process aid or carrier web in theprocess of forming the laminated structure as described herein after. Inalternative embodiments, the spunbonded polypropylene nonwoven materialmay have a greater or lower basis weight, or it may be replaced by anair laid tissue, a wet laid tissue or any of the materials describedherein before.

[0074] Process of Manufacturing the Color Printed Laminated Structure

[0075] A suitable process for manufacturing a color printed laminatedstructure comprising two layers, a first layer and a second layer, whichis a fibrous web, preferably a dry laid fibrous web, comprises at leastthe following steps:

[0076] (a)—providing the first layer and color printing it on at leastone of its surfaces,

[0077] (b)—then providing fibers onto the first layer to form the secondlayer,

[0078] (c)—then applying bonding means, preferably latex binder, ontothe outer surface of said second layer and curing and/or

[0079] (d)—applying bonding means, preferably latex binder, onto theouter surface of said first layer and curing

[0080] When both Steps (c) and (d) are carried out, this might be donein any sequence first (c) then (d) or first (d) then (c) orsimultaneously, provided (a) and (b) are operated before (c) and (d).

[0081] The first layer might be color printed on its inner or outersurfaces or both of them. Preferably the first layer is color printed onits inner surface, the surface in face-to-face relation with (i.e.,directly adjacent to) the second layer in the laminated structure. Thisconstruction is preferred as it further improves the abrasion resistance(color rub-off resistance) properties of the whole color printedlaminated structure as well as further reduces occurrence of colorbleeding, especially when used as a secondary topsheet in an absorbentarticle for feminine protection.

[0082] Advantageously the first layer is printed with a mono-color imageor with a multi-color image. In this later embodiment where multi-colorprinting is desired tight registration is suitable. Tight registrationrefers to the precise alignment of the different colors comprising animage. Inherent difficulties in achieving tight registration include thedistance between the color printing stations, the uniformity of theprinting substrate, and the extensibility of the printing substrate.

[0083] Any printing process known in the art, for example, letterpress,lithography, gravure or silk screen are suitable for use herein.Suitable printing processes are, for example, described in U.S. Pat. No.5,695,855. The colored image may be obtained by generating a halftone inany conventional way. Thus, a preferred printing process is half toneprinting. As used herein, the term “halftone” means breaking up acontinuous solid tone into a plurality of tiny individual indicia ofvarying sizes, shapes and/or tonal intensities (tonalities).

[0084] The inks used to form the colored image may be any ink known inthe art such as those described in, for example, U.S. Pat. No.5,695,855. The inks used should be safe for human use and should nothave environmentally deleterious effects. The inks chosen should, ofcourse, be suitable for the intended printing process. Thus, forexample, letterpress and lithographic inks are fairly stiff and requirelong ink roller trains on the press, to obtain the required flow andfilm thickness for printing. In contrast, gravure and flexographic inksare very fluid and dry mainly by solvent evaporation. Inks for screenprinting are paint-like in their consistency and drying characteristics.The inks used herein once applied onto the absorbent article andoptionally stabilized thereon should be substantially insoluble in thefluids (e.g., menses and/or urine) to be absorbed by the absorbentarticle.

[0085] The present invention preferably utilizes flexographic printingto provide the proper balance of cost effective, high speed, highquality printing suitable for printing the first layer, preferablynonwoven fibrous web, while maintaining the tactile softness of thelayer. Flexography is a printing technology, which uses flexible raisedrubber or photopolymer plates to carry the image to a given substrate.The flexible plates carry a typically low-viscosity ink directly ontothe substrate. The quality of flexographic print in recent years hasrapidly advanced such that, for many end-uses, it is comparable tolithographic or gravure printing.

[0086] The types of plates that can be used with the process of thepresent invention include plates identified as DuPont Cyrel.RTM. HL,PQS, HOS, PLS, and LP, which may be obtained from E. I. DuPont deNemours & Co., Inc., 1007 Market Street, Wilmington, Del. 19898; a plateidentified as BASF Nyloflex.RTM., which may be obtained from BASF, 1255Broad Street, Clifton, N.J. 07015; and a plate identified asFlex-light.RTM. type FL-SKOR.RTM., which may be obtained from W.R. Grace& Co., 5210 Phillip Lee Drive, Atlanta, Ga. 303336. Others include laseretched vulcanized rubber cylinders, such as those supplied by LuminiteProducts Corporation, 115 Rochester Street, Salamanca, N.Y. 14779, or byFlexo Express, 270 Rochester Street, Salamanca, N.Y. 14779; or rubberprinting plates, such as those supplied by Fulflex, Incorporated, P.O.Box 4549, Middleton, R.I. 02804. The rubber plates and vulcanizedcylinder could be natural rubber, EPDM, nitrites, or urethanes.

[0087] Although flexographic printing is preferred herein, otherprinting methods known to those skilled in the art might be usedincluding screen printing, rotogravure printing, ink jet printing andthe like.

[0088] In comparison to flexographic printing, screen printing equipmentis relatively costly and cannot be run as fast as flexographicequipment.

[0089] Rotogravure printing uses an engraved print roll that increasesthe life of the print pattern and provides higher definition, butrotogravure entails higher cylinder costs and does not give consistentink depositions on many non-woven substrates. However, rotogravureequipment can be used with water-based, solvent-based, and hot-melt,adhesive-based inks.

[0090] Ink jet printing equipment generally requires inks that have avery low viscosity, often in the range of 1 to 10 centipoises, in orderto achieve appropriate processing and application. Water-based andadhesive-based inks can be brought into this range. An advantage of inkjet printing equipment is the relatively high speed at which it can berun. Although only one color can be used per jet, multiple jets can beused to provide multiple colors.

[0091] In printing processes, the ink would cover or print in a varyingmanner on bond points (i.e., those points where fibers cross and arebonded together), on the fibers themselves, and where the fibers merelycross, but are not bonded together. The varying ink printing or contrastis identified as a paler or more washed-out color, or even a change ofcolor, due to the differences of surface characteristics between thebond points, fiber crossover regions, and the fibers themselves.

[0092] Suitable inks to be used herein include the so-called water-basedink and solvent-based ink.

[0093] A “solvent-based” ink does not use water as the mobile phase tocarry various pigments, resin(s) or binder(s), and additives, such aswax. Typically, “solvent-based” inks use one or more of various organicsolvents such as alcohols, esters, aliphatics, and aromatics tosolubilize these components. Solvents that solubilize resins well aregenerally referred to as “active”, while those that are not “active” arecalled “diluents”. A “water-based” ink typically uses waterpredominantly as the mobile phase. Resins used with water-based inkstypically are emulsions, and can be dispersions in some cases. Othersolvents may be added to act as co-solvents or coalescing agents to helpemulsions form a continuous film.

[0094] Solvent-based inks that typically use aliphatic hydrocarbons withcommon binder types, such as polyamide, shellac, rosin esters,nitro-cellulose, and styrene-maleic are suitable for use herein. Highlypreferred solvent-based ink includes non-catalytic, block urethaneresin, which have demonstrated superior durability over traditionalflexographic binders, such as styrene-maleic, rosin-maleic, acrylicsolutions.

[0095] Desired solvent blends include blends ranging in volume up toabout 50% of various acetates such as ethyl acetate, N-propyl acetate,isopropyl acetate, isobutyl acetate, N-butyl acetate, and blendsthereof; up to about 10% of various alcohols including ethyl alcohol,isopropyl alcohol, normal propyl alcohol, and blends thereof; and up to75% glycol ethers including Ektasolve.RTM. EP (ethylene glycolmonopropyl ether), EB (ethylene glycol monobutyl ether), DM (diethyleneglycol monomethyl ether), DP (diethylene glycol monopropyl ether), andPM (propylene glycol monomethyl ether), which can be obtained fromEastman Chemical, P.O. Box 431, Kingsport, Tenn. 37662. Other suitablesolvents can also be obtained from Union Carbide Chemicals, 39 OldRidgebury Road, Danbury, Conn. 06817. A desired solvent blend is a blendof about 50% to about 75% glycol ether, about 25% to about 35% N-propylacetate, and about 15% to about 25% N-butyl acetate. Other glycols canbe used such as DOWANOL.RTM., obtainable from Dow Chemical, Midland,Mich. 48640.

[0096] Suitable water-based inks for use herein include emulsions thatare stabilized in water-ammonia, and may contain alcohols, glycols, orglycol ethers as co-solvents. Indeed, it is common practice to addorganic solvents (7% maximum) to water-based inks: alcohols, e.g.,propan-2-ol—to speed up drying and assist wetting, glycols, e.g., monopropylene glycol to slow down drying, glycol ethers, e.g., dipropyleneglycol mono methyl ether to aid film formation. Such solvents arecommodity chemicals, commercially available from various companies.Highly preferred water-based ink includes self-crosslinking acryliccopolymer emulsion, which has demonstrated superior durability overtraditional non-crosslinking binders such as acrylic solutions anddispersion copolymers.

[0097] The water-based inks and solvent-based inks also includecoloration in addition to the binders and solvents/water. Coloration istypically imparted by the use of inert pigments and dyes, collectivelyreferred to as pigments for purposes of the present invention, which canbe added in levels of about 0.25% to about 40% on a dry weight basis andpreferably between 1 and 10%.

[0098] The most common pigments include azo dyes (for example, SolventYellow 14, Dispersed Yellow 23, and Metanil Yellow), anthraquinone dyes(for example, Solvent Red 111, Dispersed Violet 1, Solvent Blue 56, andSolvent Orange 3), xanthene dyes (Solvent Green 4, Acid Red 52, BasicRed 1, and Solvent Orange 63), azine dyes (for example, Jet Black), andthe like.

[0099] Major organic pigments include dairylide yellow AAOT (forexample, Pigment Yellow 14 CI#21095), dairylide yellow AAOA (forexample, Pigment Yellow 12 CI#21090), Hansa Yellow, CI Pigment Yellow74, Phthalocyanine Blue (for example, Pigment Blue 15), lithol red (forexample, Pigment Red 52:1 CI#15860:1), toluidine red (for example,Pigment Red 22 CI#12315), dioxazine violet (for example, Pigment Violet23 CI#51319), phthalocyanine green (for example, Pigment Green 7CI#74260), phthalocyanine blue (for example, Pigment Blue 15 CI#74160),naphthoic acid red (for example, Pigment Red 48:2 CI#15865:2).

[0100] Inorganic pigments include titanium dioxide (for example, PigmentWhite 6 CI#77891), carbon black (for example, Pigment Black 7 CI#77266),iron oxides (for example, red, yellow, and brown), ferric oxide black(for example, Pigment Black 11 CI#77499), chromium oxide (for example,green), ferric ammonium ferrocyanide (for example, blue), and the like.

[0101] Besides the solvent and pigments, the inks preferably comprises abinder or mixtures thereof. The binder helps stabilizing the pigmentonto the support to which it is applied to. Typically thepigment-to-binder ratios is typically from 1:20 to 1:2 and preferablyranges up to about 1:1.7.

[0102] Waxes are also included in the present invention to increase theslip and improve the rub-resistance of the inks of the printedpolyolefin substrate. Common classifications of waxes include animal(for example, beeswax and lanolin), vegetable (for example, carnauba andcandellilia), mineral (for example, paraffin and microcrystalline), andsynthetic (for example, polyethylene, polyethylene glycol, andTeflon.RTM.). A recommended range is between about 0.5% to about 5% waxbased on the total formula weight.

[0103] The printing provided can be single color or multiple-colordepending upon the aesthetic needs. According to the present inventionit is desirable to have an image in one or more colors or tonalitiesprinted on at least one surface of the first layer such that it isvisible to the wearer of an absorbent article comprising the laminatedstructure for example as a topsheet, preferably secondary topsheet. Withfeminine protection absorbent articles, for example, it is desirable tomake the article as attractive and as fun as possible to wear in orderto encourage woman especially teens to feel better and more relaxedduring their periods.

[0104] The process of manufacturing color printed laminated structureaccording to the present invention will now be described by way ofexample, with reference to the accompanying drawings in which:

[0105]FIG. 1 is a simplified schematic illustration of a preferredembodiment for the manufacture of the dry laid fibrous laminatedstructure of the present invention. In accordance with this embodiment,the air forming system, indicated generally by the numeral 100, includesa distributor unit 101 disposed transversely above a continuous formingscreen, the color printed first layer (e.g. color printed nonwoven) 102,mounted on rollers 103 and driven by a suitable motor (not shown), andvacuum means or suction box 104 is positioned beneath the screen.Upstream of the distributor unit 101 is a defibrator or feeder 105, suchas a hammermill or Rando-Feeder, where bales, laps or the like (forexample wood pulp provided per roll 106) are defiberized. The fibres maybe cleaned and/or blended if necessary or desired depending largely onthe type of fibres used, the blend of fibres used, and the end productsought. For example, wood pulp fibres can be blended with syntheticfibres and applied as a blend by a single distributor, or differentfibres can be each conveyed by a different distributor to the firstlayer to form separate plies or layers.

[0106] The porous forming screen, the color printed first layer, e.g.,nonwoven layer 102, is essentially coextensive with the distributors101, and the vacuum belt or suction box 104 beneath the first layerdraws the air stream downwardly and conveys the fibres to the surface ofthe first layer, thereby forming plies or a loose web, i.e. second layerof the laminated structure (air laid fibrous web). At this stage in theprocess, the resulting laminated structure exhibits little integrity,and the vacuum means 104 retains the loose, fibrous air laid web on thefirst layer 102. The air laid web has an outer surface that faces thedistributor and an inner surface, opposite to the outer surface, thatfaces the forming first layer 102. At least one of the surfaces of thefirst layer 102 is color printed before undergoing the manufacturing ofthe dry laid fibrous laminated structure.

[0107] It should be understood that the system may be modified tocontrol the composition and thickness of the end laminated structure.For example, the distributor unit can comprise a plurality of individualdistributors, and although FIG. 1 shows schematically two distributorsrespectively at 101A and 101B, the number of distributors and particulararrangement can be altered or varied depending on such factors asmachine speed, capacity, type of fibres, and end product desired.

[0108] In one embodiment herein the laminated structure formed on thefirst layer 102 might incorporate therein a particulate material. Forexample the particulate materials might be an absorbent gelling materialor an odour control means, both in particle or powder form, or a mixturethereof. In such an embodiment a dosing unit or feed hopper (not shown),containing the particulate materials is for example positioned inbetween the distributor units, e.g., between distributors 101A and 101B.

[0109] In a preferred embodiment herein a thermoplastic polymericmaterial in finely divided form, preferably in powder form, ispreferably added to the fibrous web. In the embodiment shown in FIG. 1the thermoplastic polymeric material in powder form is supplied to thedosing unit 108 from the container 107, the dosing unit being locatedbetween the distributors 101A and 101B. In this manner, thethermoplastic polymeric materials in powder form are deposited betweenplies of fibres laid by each distributors 101A and 101B. That is, thethermoplastic polymeric materials are discharged from hopper 108 ontothe moving layer of fibres laid down by distributor 101A, and the ply offibres laid down by distributor 101B is laid over the thermoplasticpolymeric material.

[0110] It should be understood, however, that the plies are relativelyporous, and therefore the thermoplastic polymeric material tend todistribute somewhat within adjacent plies. Therefore the resultingfibrous web comprises the thermoplastic polymeric material concentratedintermediate the thickness of the web, forming a region of the web inwhich the fibres constitute a lower percentage as compared to thethermoplastic polymeric material. Indeed it is preferred that thethermoplastic polymeric material is distributed within the thickness ofthe web, intermediate the outer and inner surfaces thereof.Alternatively the thermoplastic polymeric material (e.g., polyethylene)is mixed together to the fibers (typically cellulose fibres) in eachdosing unit. For example the dosing unit 101 a might contain 50% ofcellulose and 50% of polyethylene, while the dosing units 108 and 101 bmight contain 75% cellulose and 25% polyethylene.

[0111] The resulting laminated structure 112 might require furtherstabilization. According to the embodiment of the present inventionillustrated in FIG. 1 the laminated structure is bonded on one, orpreferably both outer surfaces (outer surface of the first layer and/orouter surface of the second layer, i.e., air laid fibrous web) by meansof the application of a latex composition. In the embodiment shown thelaminated structure is preferably first passed between compressionrollers 109, which may be heated, to densify the structure, but thisstep is optional. This densification step can enhance the penetration ofthe latex binder into the laminated structure, and the degree or percentof densification can vary depending on such factors as basis weight ofthe laminated structure, the desired degree of penetration of the latexbinder into the laminated structure, and the end product sought.

[0112] After the (optional) compression rollers the laminated structureis transported to a suitable dispensing means 110, such as a spraynozzle, doctor blade, roller applicator, or the like, where a latexbinder is applied to the outer surface of the fibrous web (air laidfibrous web) of the laminated structure. A vacuum applied by a suctionbox (not shown) is positioned beneath the dispensing means 110 and thelaminated structure 112, and helps to draw the latex binder into thestructure. The dispensing means or applicator 110 is essentiallycoextensive with the width of the fibrous air laid web, and preferably asubstantially uniform coating is applied to the fibrous web surface.However, the latex binder may be applied as a non-uniform, random orpattern coating, and because the latex binder is water-based, it willdiffuse throughout the fibrous web/laminated structure and function as abinder when cured.

[0113] The latex binder when cured imparts integrity to the fibrousweb/laminated structure. The extent or degree of penetration of thelatex binder into the web/laminated structure might be controlled bycontrolling the amount of latex applied and by controlling the vacuumapplied to the web/laminated structure (the vacuum helps to draw thelatex into the web/laminated structure). The amount of the latex binderis also kept to such an extent that it does not impair the absorbencyand softness characteristics of the fibrous web and hence the resultinglaminated structure.

[0114] The latex binder is usually applied as an aqueous emulsion, andcan be a thermosetting plastic. In order to activate the latex, thelatex emulsion might contain a suitable curing agent or cross-linkingagent, and after the web is coated, the latex is cured to effectcross-linking. Most typically, curing is accomplished by passing thecoated web/laminated structure through a hot air oven or through an airdrier 111, and the temperature typically ranges from 100° C. to 260° C.,but this depends upon the specific type of latex resin used, upon thecuring agent or cross-linking agent, upon the amount of latex, thethickness of the web, the degree of vacuum, and the machine speed.

[0115] It is desirable to coat the outer surface of the first layer 102of the resulting laminated structure 112 with latex binder as well, andthis is readily accomplished by the dispensing means 118 as thelaminated structure is conveyed via there under via pulleys 113 and 114.This step is desirable as beside stabilizing the laminated structure italso further stabilizes the color printing on the first layer, therebyfurther reducing color-bleeding in use conditions and color rub-off.Coating the outer surface of the first layer with latex is especiallydesired in the embodiment of the invention wherein the outer surface ofthe first layer is color printed. The second dispensing means 118includes a suction box (not shown). This second latex coating islikewise cured by passing the laminated structure through a second oven115 within about the same temperature range.

[0116] In the preferred embodiment herein wherein thermoplasticpolymeric material has been added as shown in FIG. 1 per dosing unit108, this material contributes to stabilizing the structure herein.Indeed bonds among the fibres are generated by the melting of theindividual particles of thermoplastic polymeric material in powder formwhen in oven 111 and/or 115; as it melts, the thermoplastic polymericmaterial forms “bridges” connecting directly the fibres.

[0117] The overall surface area of the bond points represents a smallfraction of the surface area of the fibres that are involved in thebonding, the characteristics of which thus remain almost unchanged.

[0118] The thermoplastic polymeric material in finely divided form, e.g.in form of powder has the purpose of bonding the particulate materialand, at least partially, the fibres of the dry laid absorbent structuretogether by melting and forming discrete, spaced-apart bond points amongthe particles and the fibres. The thermoplastic polymeric material canalso be used in other finely divided forms, e.g. in form of fibrils.

[0119] The melting is preferably conducted at temperatures so as to notaffect the characteristics of the other constituents, i.e., fibres andoptional particulate materials. These preferred characteristics can beachieved by a thermoplastic polymeric material in finely divided formhaving a melt flow index (M.F.I.), evaluated by the ASTM method D1238-85 under conditions 190/2.16, of at least 25 g/10 min, preferablyat least 40 g/10 min, and even more preferably at least 60 g/10 min.

[0120] If the fibres of the dry formed fibrous structure are shortcellulose fibres, it is preferable to use a thermoplastic polymericmaterial composed of powder of high-density polyethylene with maximumdimensions of the particles of about 400 microns, characterized by amelt flow index of about 50 g/10 min, in a quantity between 12 g/m² and90 g/m²

[0121] The resulting stabilized laminated structure 117 exiting from thelast oven now exhibits sufficient integrity and can be rolled (e.g., asshown in FIG. 1 on a winding/roll slitting 116) or alternatively cut andpackaged, etc.

[0122] The laminated structure made in accordance with the foregoingprocess is illustrated in FIG. 2 and FIG. 3. The first layer of thelaminated structure comprises randomly distributed fibres, such as woodpulp fibres. In the preferred embodiment herein wherein the first layercomprises the thermoplastic polymeric material in powder formdistributed randomly among the fibers of the first layer, this materialperforms the bonding of at least part of the fibres of the first layerof the laminated structure, i.e. those fibres that enter in contact withthe thermoplastic polymeric material. Both outer surfaces (2, 6 and 20,60) of the laminated structure (a,b) bear a latex coating, indicated inthe drawing by lines 8,9 and 80,90. The latex penetrates or impregnatesthe outer surfaces of the structure to some degree and partially coatssome of the fibres (not shown).

[0123] In an alternative embodiment of the present invention, notillustrated, the latex coating first is applied on the outer surface ofthe first layer of the structure and cured before being applied on theouter surface of the second layer, i.e. air laid fibrous web, or bothsteps are carried out simultaneously.

[0124] Absorbent Article

[0125] While the present invention will be described herein after in thecontext of sanitary napkins and panty liners, the invention might alsobe applicable as mentioned herein before for other protection thanfeminine protection, like adult incontinence protection or babyprotection.

[0126] In a preferred embodiment herein the absorbent article accordingto the present invention comprises a topsheet, an underlying layervisible through the topsheet, an absorbent core and a backsheet. Theunderlying layer visible through the topsheet is directly adjacent tothe topsheet, i.e. in face-to-face relation with the topsheet, typicallylocated between the topsheet and the absorbent core. The underlyinglayer is made of the color printed laminated structure according to thepresent invention. Preferably the outer surface of the first layer ofthe laminated structure is facing the wearer (hence might also be calledherein wearer facing surface) and the outer surface of the second layerof the laminated structure is facing the garment of the wearer (hencemight also be called garment facing surface). In the preferredembodiment herein the underlying layer is the so-called secondarytopsheet layer.

[0127] The Topsheet

[0128] The topsheet for use in the present invention also called hereinafter primary topsheet is formed from at least one primary top layer. Ina preferred embodiment herein the primary topsheet is in face-to-facerelation to an underlying layer, also called herein secondary topsheet.

[0129] The primary topsheet should be compliant, soft feeling, andnon-irritating to the wearer's skin. The primary topsheet is fluidpervious, permitting fluids (e.g., menses and/or urine) to readilypenetrate through its thickness. The underlying layer, typically thesecondary topsheet, is visible through the primary topsheet so to allowrecognition of color printed on the secondary topsheet per human eyes.The primary topsheet is typically provided with some regions, which aretransparent as opposed to opaque. By ‘opaque’ it is referred herein to amaterial, which inhibits the passage of light, such that a color printedimage located opposite the material can not be viewed by naked eyes. By‘transparent’ it is referred to material through which light passes suchthat color printed image located opposite the transparent material canbe viewed by the naked eye. Preferably herein the primary topsheet isprovided with at least some regions which are transparent and mostpreferably the transparent areas represent at least 20%, preferably atleast 50%, more preferably at least 90% and most preferably 100% of thewhole topsheet (i.e. the topsheet is preferably completely made oftransparent material). As a general rule a material will be consideredto be transparent when it has a light transmission of greater than 50percent, preferably greater than 80 and most preferably greater than 90.

[0130] A suitable primary topsheet can be manufactured from a wide rangeof materials such as woven and non woven materials; polymeric materialssuch as apertured formed thermoplastic films, apertured plastic films,and hydroformed thermoplastic films; and thermoplastic scrims. Suitablewoven and non woven materials can be comprised of natural fibers (e.g.,wood or cotton fibers), synthetic fibers (e.g., polymeric fibers such aspolyester, polypropylene, or polyethylene fibers) or from a combinationof natural and synthetic fibers or bi-/multi-component fibers.

[0131] Preferred primary topsheets for use in the present invention areselected from high loft non-woven topsheets and apertured formed filmtopsheets. Apertured formed films are especially preferred for theprimary topsheets because they are pervious to body exudates and yet nonabsorbent and have a reduced tendency to allow fluids to pass backthrough and rewet the wearer's skin. Thus, the surface of the formedfilm that is in contact with the body remains dry, thereby reducing bodysoiling and creating a more comfortable feel for the wearer. Suitableformed films are described in U.S. Pat. No. 3,929,135; U.S. Pat. No.4,324,246; U.S. Pat. No. 4,342,314; U.S. Pat. No. 4,463,045; and U.S.Pat. No. 5,006,394. Particularly preferred micro apertured formed filmprimary topsheets are disclosed in U.S. Pat. No. 4,609,518 and U.S. Pat.No. 4,629,643. A preferred primary topsheet for the present inventioncomprises the three-dimensional formed film described in one or more ofthe above patents and marketed on sanitary napkins by The Procter &Gamble Company of Cincinnati, Ohio as “DRI-WEAVE”. WO 97/14388 alsodescribes a suitable apertured primary topsheet.

[0132] Preferred primary topsheets have apertures being dimensioned topermit show-through (or visualisation) of the colored printed image onthe secondary topsheet. The pattern of apertures might be regularlyspaced or random.

[0133] A preferred regularly spaced first pattern of apertures comprisesa macroscopically expanded pattern of irregularly shaped pentagonalapertures described in U.S. Pat. No. 4,463,045. The primary topsheetdescribed in U.S. Pat. No. 4,463,045 is a three-dimensional formed filmcomprising an array of sub-patterns, each sub-pattern comprising fourirregular pentagonal apertures forming an irregular hexagon. Anotherpreferred primary top layer exhibits apertures arranged in an ordered orpseudo-random array. A suitable ordered array may be a regular square,rectangular, rhomboidal or hexagonal array, the apertures themselvesbeing square or, alternatively, circular or slightly elliptical asdescribed in U.S. Pat. No. 4,780,352. The interspacing between adjacentapertures may be about 1.4 mm. Overall, the ratio between the surfaceoccupied by the apertures and the whole surface of the primary top layeris typically within the range 10-50%, depending on the requirements ofuse and the strength characteristics of the materials used. Preferably,the open area is about 25%. It will of course be appreciated that theapertures may be arranged in an array other than a regular square,rectangular, rhomboidal or hexagonal array or other than in apseudo-random array.

[0134] Suitable apertures may be made by a perforating or punchingaction. A suitable perforating station would constitute twocounter-rotating rollers, the lower roller of which acts as a rotarysupport and has a generally smooth surface and the upper roller of whichhas teeth or projections arranged in the array corresponding to thefirst pattern. Feeding of the primary top layer through the perforationstation causes the teeth or projections of the upper roller to penetratethe primary top layer, thereby perforating its structure, as describedin U.S. Pat. No. 4,780,352.

[0135] Primary topsheet being made of transparent/translucent material,in contrast to white conventional topsheet are highly preferred herein.Advantageously the use of such transparent topsheet enhances thevisibility of the colored laminated structure positioned beneath theso-called primary topsheet. Such transparent materials are typicallyavailable by simply reducing or even omitting white pigmentconventionally used during manufacturing thereof, like titanium oxide.The topsheet can be completely transparent or can be provided only withregions of transparency. Such material although provided with inherenttransparency can further comprise apertures.

[0136] An example of transparent topsheet is commercially availableunder code name Ris CPM-Clear from Tredegar-Terrehaute—Ind.

[0137] Alternatively the primary topsheet material might be made ofconventional material (white) and treated to render it transparent. Suchtreatment generally consists of applying thermal energy through adiscontinuous heat bonding, sonic bonding or pressure embossingoperation.

[0138] The primary topsheet typically extends across the whole of theabsorbent structure and outside the area coextensive with the absorbentstructure.

[0139] When referring to the primary topsheet, a multi layer aperturedstructure or a mono layer apertured structure are each contemplated.

[0140] Absorbent Core

[0141] Absorbent cores suitable for use in the present invention may beselected from any of the absorbent cores or core systems known in theart. As used herein, the term “absorbent core” refers to any material ormultiple material layers whose primary function is to absorb, store anddistribute fluid. In one embodiment herein the color printed laminatedstructure of the invention might also be used as part of the absorbentcore or as the absorbent core in its entirety.

[0142] Backsheet

[0143] The backsheet primarily prevents the exudates absorbed andcontained in the absorbent structure from wetting garments that contactthe absorbent product such as underpants, pants, pyjamas andundergarments. The backsheet is preferably impervious to fluids (e.g.menses and/or urine) and is preferably manufactured from a thin plasticfilm, although other flexible liquid impervious materials can also beused.

[0144] The backsheet can comprise a woven or nonwoven material,polymeric films such as thermoplastic films of polyethylene orpolypropylene, or composite materials such as a film-coated nonwovenmaterial.

[0145] Preferably the backsheet of the absorbent article is moisturevapour permeable and thus comprises at least one gas permeable layer.Suitable gas permeable layers include two dimensional, planar micro- andmacro-porous films, macroscopically expanded films, formed aperturedfilms and monolithic films. The apertures in said layer may be of anyconfiguration, but are preferably spherical or oblong and may also be ofvarying dimensions. The apertures preferably are evenly distributedacross the entire surface of the layer. However layers having onlycertain regions of the surface having apertures are also envisioned.

[0146] A preferred sanitary napkin or panty liner of the presentinvention has a pair of conventional flaps or wings. If desired theseflaps or wings might also comprise a color printed laminated structureaccording to the present invention.

[0147] The invention will now be further described, by way of example,with reference to the accompanying drawings, in which:

[0148]FIG. 5 illustrates a top plan view of a sanitary napkin 20 viewedper its wearer facing surface, said napkin 20 comprising one primary toplayer 21 and a secondary topsheet layer 23 visible through the primarilytopsheet layer 21. The secondary topsheet layer 23 is provided withcolor printed image 24 visible through the primary topsheet layer 21.The primary top layer 21 is a three-dimensional formed film exhibiting amacroscopically expanded three-dimensional pattern of irregularly shapedpentagonal apertures 22. In an alternative embodiment not shown such asanitary napkin can be embossed, embossing points are obtained asdescribed in U.S. Pat. No. 4,397,644 or WO98/27904.

[0149] An alternative sanitary napkin is illustrated in FIG. 6. Thesanitary napkin in FIG. 6 differs from the sanitary napkin illustratedin FIG. 5 only in the image color printed per flexography printing onthe first layer of the laminated structure forming the so-calledsecondary topsheet.

[0150] Referring to FIG. 5, it will be observed that the color printedimage 24 is positioned, shaped and dimensioned to be visible through theprimary topsheet, namely through the apertures thereof. In analternative embodiment the primary topsheet material per se is fullytransparent (apertured or not) (e.g., Ris CPM-Clear [X-27221] fromTredegar-Terrehaute—Ind.), the color printed image being visible throughthe entire surface of the primary topsheet.

[0151] Referring now to FIG. 4 of the accompanying drawings, there isillustrated a cross sectional view of the sanitary napkin of FIG. 5. Thesanitary napkin comprises

[0152] as a primary topsheet 21, a white apertured polyethylene formedfilm having holes of 0.889 square millimeters, basis weight of 25 g/sqmand an open area of 80% (white CPM, code name X25602 commerciallyavailable from TREDEGAR, Terrehaute—Ind.)

[0153] as a secondary topsheet 23, a color printed laminated structure(77 g/sqm) made of a 22% weight of spunbonded polypropylene nonwovenmaterial having a basis weight of 17 g/sqm, referred to as product No.1WH05-01-17B (or ‘P-9’) obtained from BBA, Linotec, color printed on itsinner surface, together with a multibonded air laid nonwoven materialmade of 68% weight cellulose and 25% weight polyethylene powder of thetotal laminated structure basis weight, 4% latex per weight of totallaminated structure applied on both side (2.5% on the multibonded airlaid and 1.5% on the spunbonded polypropylene nonwoven). (cf. FIG. 3)

[0154] a spiral layer of adhesive (H2545®, available from Ato Findley)(not shown in FIG. 4),

[0155] a white absorbent tissue core 25 with 17% super absorbent fibers,polypropylene and polyethylene bi-component fibres and cellulose (codeGH.150.1006, basis weight 150 gsm commercially available from ConcertGmbH, Falkenhagen-Germany),

[0156] a spiral layer of adhesive (H2545®, available from Ato Findley)(not shown in FIG. 4),

[0157] as backsheet, a polyethylene micro embossed film 26, commerciallyavailable from Tredegar, under code XBF 616W

[0158] stripes of panty fastening adhesive (LA203/TF1®, available fromSavare) (not shown in FIG. 4), and release paper (not shown).

[0159] Advantageously the color printed laminated structure as describedherein before as topsheet 23 (illustrated in FIG. 3) in the sanitarynapkin (illustrated in FIG. 4) has a color fastness to water whenmeasured according to ISO 105-E01 of 4, a color fastness to rubbing whenmeasured according to ISO 105-X12 in dry condition of 4 and in wetcondition of 3 and a color fastness to perspiration when measuredaccording to ISO 105-E04 of 4 (both for alkaline solution and acidsolution).

What is claimed is:
 1. A color printed liquid permeable laminatedstructure comprising at least a first liquid permeable layer and asecond liquid permeable layer, the second layer being a fibrous web, thefirst layer being color printed on at least one of its surfaces priorlaminating it to the second layer and stabilizing the laminatedstructure with a bonding means.
 2. A laminated structure according toclaim 1, wherein the first layer is a non-woven, preferably a spunbondednon-woven.
 3. A laminated structure according to claim 1, wherein thefirst layer, prior laminating it to the second layer, is color printedon at least the surface thereof directly adjacent to the second layer inthe laminated structure, the color print being visible through the firstlayer on its opposite surface.
 4. A laminated structure according toclaims 1 or 2 or 3, wherein the second layer is a dry laid fibrous web,typically comprising cellulose fibers.
 5. A laminated structureaccording to claim 4, wherein the dry laid fibrous web is an air laid.6. A laminated structure according to claim 1, wherein the bonding meansstabilizing the structure comprises a latex binder typically selectedfrom the group consisting of vinyl acetate and acrylic ester copolymers,ethylene vinyl acetate copolymers, styrene butadiene carboxylatecopolymers, and polyacrylonitriles, typically at a level of about 2% toabout 30% by weight of the total weight of the laminated structure.
 7. Alaminated structure according to claim 1, wherein the bonding meanscomprises a thermoplastic polymeric material in finely divided formdistributed into the second fibrous layer in order to bond the fibers ofsaid fibrous layer.
 8. A laminated structure according to claim 1,wherein the color for color printing the first layer is selected from arange of colors ranging from yellow to blue (440 to 580 nanometers). 9.A laminated structure according to claim 1, wherein the first layer iscolor printed with a water-based ink and preferably a self-crosslinkingacrylic copolymer emulsion.
 10. A disposable absorbent article,preferably a sanitary napkin or pantiliner, comprising a topsheet, abacksheet and a color printed laminated structure according to any ofthe preceding claims 1, 2 or 3, typically as an underlying layerdirectly adjacent to the topsheet so as to be visible through saidtopsheet.
 11. A disposable absorbent article according to claim 10,wherein said topsheet is provided with at least some regions, which aretransparent, and most preferably is completely transparent.
 12. Aprocess for manufacturing a laminated structure according to any of thepreceding claims 1 to 9, wherein the process comprises the steps of:(a)-providing the first layer, then color printing it on at least one ofits surfaces, (b)-then providing fibers onto the first layer to form thesecond layer, (c)-then applying a bonding means, preferably a latexbinder, onto the outer surface of said second layer and curing and/or(d)-applying a bonding means, preferably a latex binder, onto the outersurface of said first layer and curing wherein when both steps (c) and(d) are carried out, steps (c) and (d) might be carried in any sequence,including first (c) then (d) or first (d) then (c) or simultaneously,provided (a) and (b) are operated before (c) and (d).
 13. A processaccording to claim 12, wherein the color printing of the first layer ismade per flexography printing.
 14. An absorbent article for feminineprotection comprising a liquid permeable topsheet, an underlying layervisible through the liquid permeable topsheet, a liquid impermeablebacksheet and an absorbent core positioned between the underlying layerand the backsheet, characterized in that the underlying layer visiblethrough the topsheet is a color printed liquid permeable laminatedstructure comprising at least two liquid permeable layers, each layerhaving a pair of opposed surfaces, at least one layer of the laminatedstructure is color printed on at least a surface directly adjacentanother liquid permeable layer of the laminated structure, priorlaminating the liquid permeable layers of the laminated structuretogether.